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ESR-1659ICC-ES Evaluation Reports are not to be construed as representing aesthetics or any other attributes not specifically addressed, nor are they to be construed as an endorsement of the subject of the report or a recommendation for its use. There is no warranty by ICC Evaluation Service, LLC, express or implied, as to any finding or other matter in this report, or as to any product covered by the report. Copyright © 2012 Page 1 of 7 1000 ICC-ES Evaluation Report ESR-1659 Issued April 1, 2012 This report is subject to renewal April 1, 2013. www.icc-es.org | (800) 423-6587 | (562) 699-0543 A Subsidiary of the International Code Council ® DIVISION: 07 00 00—THERMAL AND MOISTURE PROTECTION Section: 07 21 00—Thermal Insulation Section: 07 25 00—Water-Resistive Barriers Section: 07 27 00—Air Barriers REPORT HOLDER: THE DOW CHEMICAL COMPANY 200 LARKIN CENTER 1605 JOSEPH DRIVE MIDLAND, MICHIGAN 48674 (866)-583-2583 www.dowbuildingmaterials.com EVALUATION SUBJECT: THERMAX™ INSULATION BOARDS: THERMAX™ SHEATHING; THERMAX™ LIGHT DUTY; THERMAX™ HEAVY DUTY; THERMAX™ HEAVY DUTY PLUS; THERMAX™ METAL BUILDING; THERMAX™ WHITE FINISH; AND THERMAX™ ci EXTERIOR BOARD 1.0 EVALUATION SCOPE Compliance with the following codes:  2009 and 2006 International Building Code® (IBC)  2009 and 2006 International Residential Code® (IRC)  2009 and 2006 International Energy Conservation Code® (IECC) Properties evaluated:  Physical properties  Surface-burning characteristics  Water vapor transmission  Air permeability  Attic and crawl space installation  Thermal resistance  Water-resistive barrier  Exterior walls in Types I through IV construction 2.0 USES THERMAX™ insulation boards (Sheathing, Light Duty, Heavy Duty, Heavy Duty Plus, Metal Building, White Finish and ci Exterior) are used as nonstructural thermal insulating materials. The insulation boards may be used without a thermal barrier within or on interior or exterior walls, floor and ceiling assemblies, and also in attics and crawl spaces without a thermal or ignition barrier. The boards may also be used at the perimeter of concrete slab on-grade and on the interior side of basement foundation walls. The THERMAX™ insulation boards may be used on the exterior face of exterior walls of any type of construction. When used in exterior walls in Types I, II, III, IV construction, construction must be in accordance with Section 4.3. Under the IRC, the insulation boards may be used as air- impermeable insulation under IRC Section R806.4, when installed in accordance with Sections 3.6 and 4.4. The boards may be used as an alternative to the water- resistive barrier specified in IBC Section 1403.2 and IRC Section R703.2 when installed in accordance with Section 4.2. The boards, when installed in accordance with Sections 3.6 and 4.4, may be used as an air barrier to limit air infiltration in accordance with Section 402.4 of the IECC. 3.0 DESCRIPTION 3.1 THERMAX™ Insulation Boards: THERMAX™ insulation boards have a polyisocyanurate foam plastic core material reinforced with a glass fiber mat, bonded on both sides to aluminum facers having a minimum nominal thickness of 0.9 mil (0.02 mm). The boards are available in various lengths and widths and in thicknesses between 1/2 inch and 41/4 inches (12.7 and 108 mm). The boards are classified as Type I, Class 2, materials in accordance with ASTM C1289. 3.2 WEATHERMATE™ Construction Tape and Flashing Tape: WEATHERMATE™ Construction Tape is nominally 27/8 inches (73 mm) wide and is used in conjunction with THERMAX™ brand insulation boards to seal joints between two or more edges of the boards, when the insulation boards are used as a water-resistive barrier. WEATHERMATE™ Flashing Tape, with a minimum 4-inch (102 mm) width, is used in conjunction with THERMAX™ brand insulation boards to seal joints between the boards and any openings, when the insulation boards are used as a water-resistive barrier. The installation must be as described in Section 4.2. ESR-1659 | Most Widely Accepted and Trusted Page 2 of 7 3.3 Surface-burning Characteristics: THERMAX™ insulation boards have a flame-spread index of 25 or less and a smoke-developed index of 450 or less when tested in accordance with UL 723/ASTM E84 at a maximum thickness of 41/4 inches (108 mm). 3.4 Thermal Resistance, R-values: The insulation boards have thermal resistance (R-value) at a mean temperature of 75ºF (24ºC) as shown in Table 1. 3.5 Vapor Retarder: At a minimum thickness of 1/2 inch (12.7 mm), the insulation boards have a vapor permeance of less than 0.1 perm [5.7x10-12 kg/(Pa-s-m2)] when tested in accordance with ASTM E96 (desiccant method) (Procedure A), and qualify as a Class I vapor retarder. 3.6 Air Permeability: At a minimum thickness of 1/2 inch (12.7 mm), the insulation boards are considered air-impermeable in accordance with Section R806.4 of the IRC, based on testing in accordance with ASTM E283. 4.0 INSTALLATION 4.1 General: The insulation boards must be installed in accordance with The Dow Chemical Company published installation instructions, the applicable code and this report. The manufacturer’s published installation instructions must be available on the jobsite at all times during installation. 4.1.1 Application: THERMAX™ insulation boards, at a maximum thickness of 41/4 inches (108 mm), may be used as nonstructural insulating material without a thermal barrier on any or all surfaces (wall or floor/ceiling assembly) in any type of structure. For exterior wall applications, the insulation boards must be attached with fasteners spaced a maximum of 16 inches (406 mm) on center in the field and 12 inches (305 mm) on center on the perimeter. For cementitious exterior wall coating applications, fasteners for insulation boards thicker than 11/2 inches (38 mm) must be considered for lateral resistance to ensure support for the exterior wall coatings. For interior applications, the insulation boards must be attached with fasteners spaced a maximum of 24 inches (610 mm) on center along the width of the board and a maximum of 48 inches (1219 mm) on center along the length of the board. The wall covering must be structurally adequate to resist transverse loads. All walls must be braced in accordance with IBC Sections 2308.9.3 and 2308.12.4 or IRC Section R602.10, as applicable. 4.1.2 Attics and Crawl Spaces: Where THERMAX™ insulation boards are installed in an attic and crawl space without the prescriptive ignition barrier required by IBC Section 2603.4.1.6 and IRC Sections R316.5.3 and R316.5.4, the following conditions apply: a. Attic ventilation is provided when required by IBC section 1203.2 or IRC Section R806, except when air-impermeable insulation is permitted in unvented attics in accordance with Section R806.4 of the IRC. b. Under-floor (crawl space) ventilation is provided when required by IBC Section 1203.3 or IRC Section R408.1, as applicable. c. Combustion air is provided in accordance with IMC (International Mechanical Code®) Section 701. 4.2 Water-resistive Barrier: THERMAX™ insulation boards may be used as an alternative to the water-resistive barrier requirements prescribed in IBC Section 1404.2 and IRC Section R703.2, when installed on exterior walls as described in this section. The insulation boards are installed horizontally or vertically with edge joints in contact with one another. The insulation boards must be installed directly on framing members spaced a maximum of 24 inches (610 mm) on center. The insulation boards must be attached with fasteners spaced a maximum of 16 inches (406 mm) on center in the field and 12 inches (305 mm) on center on the perimeter. When the insulation boards are attached to steel studs, the boards must be attached with screws with plastic caps or washers, long enough to penetrate the framing a minimum of 0.45 inch (11.4 mm). When the insulation boards are attached to wood studs, the boards must be mechanically attached using nails, screws or staples. The fasteners must be long enough to penetrate the framing members a minimum of 3/4 inch (19 mm). The horizontal and vertical seams and joints of the insulation boards must be covered with minimum 27/8-inch- wide (73 mm) WEATHERMATE™ Construction Tape or minimum 4-inch-wide (102 mm) WEATHERMATE™ Flashing Tape. Flashing of penetration items must be in accordance with the manufacturer’s published installation instructions. Penetrations in exterior walls must be sealed with Dow GREAT STUFF™ Gaps & Cracks sealant (ESR-1961), equivalent expanding foam sealant or an elastomeric sealant. See Figures 1 through 3. 4.3 Exterior Walls of Types I, II, III and IV Construction: 4.3.1 General: When used on exterior walls of Type I, II, III and IV construction, the assembly must comply with Section 2603.5 of the IBC and this section, and the insulation boards must be installed at a maximum thickness of 41/4 inches (108 mm). The potential heat of the THERMAX™ insulation boards is 1971 btu/ft2 (22.4 MJ/m2) per inch of thickness when tested in accordance with NFPA 259. 4.3.2 Specific Wall Assemblies: Wall assemblies complying with Section 4.3 must be as described in Tables 2 and 3. 4.4 Air Barrier: When used as an air barrier material, the insulation boards must be installed in accordance with The Dow Chemical Company’s installation instructions and this report. 5.0 CONDITIONS OF USE The THERMAX™ insulation boards described in this report comply with, or are suitable alternatives to what is specified in, those codes listed in Section 1.0 of this report, subject to the following conditions: 5.1 Installation must comply with this report, the manufacturer’s published installation instructions and the applicable code. In the event of a conflict between the manufacturer’s published installation instructions and this report, this report governs. ESR-1659 | Most Widely Accepted and Trusted Page 3 of 7 5.2 Use of the insulation boards to resist structural loads is outside the scope of this report. The walls must be braced in accordance with the requirements of the applicable code. 5.3 The insulation boards must not be used as a nailing base for exterior siding materials. All nailing must be into the wall framing as required by the siding manufacturer’s instructions or the applicable code. 5.4 Jobsite certification and labeling of the insulation must comply with IRC Section N1101.4 and 2009 IECC Section 303.1.1 or 2006 IECC Sections 102.1.1 and 102.1.11, as applicable. 5.5 Use of insulation in areas where the probability of termite infestation is “very heavy” must be in accordance with IBC Section 2603.8, 2009 IRC Section R318.4, or 2006 IRC Section R320.5, as applicable. In these areas, the insulation must not be installed on the exterior of the foundation walls or below floor slabs on grade or in contact with soil. Also, in these areas, there must be a clearance of 6 inches (152 mm) or greater between the foam plastic insulation and exposed earth. 5.6 When the insulation boards are used on exterior walls of buildings of Type I, II, III or IV, construction must be as described in Section 4.3. 5.7 THERMAX™ insulation boards are manufactured by The Dow Chemical Company, under a quality control program with inspections by Intertek Testing Services NA, Inc. (AA-690). 6.0 EVIDENCE SUBMITTED 6.1 Data in accordance with the ICC-ES Acceptance Criteria for Foam Plastic Insulation (AC12), dated February 2011. 6.2 Data in accordance with the ICC-ES Acceptance Criteria for Foam Plastic Sheathing Panels Used as Water-resistive Barriers (AC71), dated February 2003 (editorially revised March 2011). 6.3 Reports of air leakage tests in accordance with ASTM E283. 6.4 Reports of water vapor transmission tests in accordance with ASTM E96. 6.5 Reports of room corner fire tests in accordance with UL 1715 and NFPA 286. 6.6 Reports of fire tests in accordance with NFPA 259. 6.7 Reports of fire propagation characteristics tests in accordance with NFPA 285. 6.8 Engineering analysis addressing use of alternative ignition barriers for use with NFPA 285–tested assemblies. 7.0 IDENTIFICATION The THERMAX™ insulation boards described in this report are identified by a label on the board or packaging material bearing the manufacturer’s name (The Dow Chemical Company), the plant code or address, the product name, the name of the inspection agency (Intertek Testing Services NA, Inc.), and the evaluation report number (ESR-1659); except for those products that are used in Type I, II, III and IV construction, which must always have the above-noted information printed on the boards. WEATHERMATE™ Construction Tape and WEATHERMATE™ Flashing Tape are identified with the product names. TABLE 1—THERMAL RESISTANCE (R-VALUES) THICKNESS (inches) R-VALUE (°F.ft2.h/Btu at 75°F MEAN TEMPERATURE) 1.0 6.5 2.0 13.0 41/4 26 For SI: 1 inch =25.4 mm; 1°F.ft2.h/Btu = 0.176 K.m2/W. ESR-1659 | Most Widely Accepted and Trusted Page 4 of 7 TABLE 2—NFPA 285 COMPLYING WALL ASSEMBLIES FOR MAXIMUM 4.25-INCH-THICK THERMAX™ INSULATION BOARD Base Wall System – Use either 1, 2, 3 or 4 1 – Concrete Wall 2 – Concrete Masonry Wall 3 – Standard Clay Brick Wall 4 – Steel Studs (minimum 3 5/8” deep, minimum 20-gauge, maximum 24-inch OC, lateral bracing every 4 ft. vertically) with one of the following installed on the interior face side of the stud wall: a. 1 layer or 1/2” or 5/8” Type X gypsum wallboard (interior face) b. W.R Grace’s Monokote Z-3306, 3/8” thick minimum, installed over: i. Cavity Insulation Item 2 or ii. THERMAX™, any thickness up to 4.25 inches c. International Cellulose Corporation’s Ure-K thermal barrier system (ESR-2110) – 1.25 inches minimum installed over: i. Cavity Insulation Item 2 or ; ii. Dow THERMAX™, any thickness d. Specialty Products, Inc. Flame Seal-TB™ coating applied at 25 mils wet thickness (18 mils dry, 65 ft2/gal) over Cavity Insulation Item 2 e. International Fireproof Technology, Inc. DC 315 applied at 18 wet mils thickness over 4 dry mils of primer over Cavity Insulation Item 2 Floorline Firestopping 4 lb/ft3 Mineral Wool in each stud cavity and at each floorline. Mineral wool to be attached with Z-clips or equivalent (see Figure 4) Cavity Insulation – Use either 1, 2, 3 or a combination of 2 and 3 1 – None 2 – Full stud depth or less thickness of Dow STYROFOAM™ Spray Polyurethane Foam CM2030, CM2045 or CM2060 (ESR-2670). Use exterior sheathing as substrate to apply onto and cover the width of the cavity including inside the stud flange 3 – Fiberglass batt insulation (faced or unfaced) complying with the applicable code Exterior Sheathing – Use either 1, 2 or 3 1 – None 2 – 1/2-inch thick, exterior type gypsum sheathing complying with the applicable code 3 – 5/8-inch thick, exterior type gypsum sheathing complying with the applicable code Water-resistive Barrier Applied to Exterior Sheathing – Use 1 or 2 1 – None 2 – Any of the following: a. WEATHERMATE™ - Dow Chemical (ESR-2862) b. WEATHERMATE™ Plus – Dow Chemical (NER-640) c. Tyvek® CommercialWrap® - DuPont (ESR-2375) d. Backstop® NT – Dryvit e. Barritech™ VP – Carlisle f. AIR-SHIELD™ LMP (black only) – W.R. Meadows g. Green Guard® Max Building Wrap – Pactiv (ESR-2906) h. Perm-A-Barrier® VPS – W.R. Grace *Note: All barriers to be installed in accordance with manufacturer’s installation instructions, the applicable ICC-ES evaluation report and the applicable code Exterior Insulation – Use 1, 2, 3 or 4 1 – None. Exterior Sheathing MUST be Item 2 or 3 as specified under exterior sheathings above 2 – Dow THERMAX™ Insulation Board (Thickness: 5/8-inch minimum, 4.25-inch maximum) 3 - Dow STYROFOAM™ Spray Polyurethane CM2030, CM2045 or CM2060 (Thickness: 3.5-inch Maximum) in accordance with ESR-2670 4 – Combination of 2 (THERMAX™ Insulation Board) and 3 (STYROFOAM™ Spray Polyurethane CM2030, CM2045 or CM2060). The combined thickness of 2 and 3 do NOT exceed 4.25-inches Water-resistive Barrier Applied to Exterior Insulation – Use 1, 2 or 3 1 – None 2 – WEATHERMATE™ - Dow Chemical (ESR-2862) 3 – WEATHERMATE™ Plus – Dow Chemical (NER-640) Flashing Flash all exterior insulation joints and veneer tie penetrations with one of the following: 1 – Dow WEATHERMATE™ Flashing – Maximum 4-inch wide 2 – Asphalt or Butyl-based flashing tape – Maximum 4-inch wide (AAMA 71 or ICC-ES AC148 complying) Optional: Spray primer to aid in adhesion of either 1 or 2 applied at a maximum of 5-inches wide Exterior Veneer – Use 1, 2, 3, 4, 5 or 6 1 – Brick. Use standard nominal 4-inch thick, clay brick. Use standard brick veneer anchors installed vertically on each stud at a maximum of 24-inch o.c. creating a 2-inch maximum air gap between the exterior insulation and brick 2 – Stucco1. Minimum 3/4-inch thick, exterior cement plaster and lath. An optional secondary water- resistive barrier can be installed between the exterior insulation and the lath. The secondary water- resistive barrier must not be full-coverage asphalt or butyl-based self-adhered membranes 3 – Limestone – Minimum 2-inch thick installed using any standard non-open-joint installation technique such as ship-lap 4 – Natural Stone Veneer – Minimum 2-inch thick installed using any standard non-open-joint installation technique such as ship-lap 5 – Cast Artificial Stone complying with ICC-ES AC51 – Minimum 1 1/2-inch thick installed using any standard non-open-joint installation technique such as ship-lap 6 – Terracotta2 Cladding– Minimum 1 1/4-inch thick installed using any standard non-open-joint installation technique such as ship-lap For SI: 1 inch = 25.4 mm. 1Cladding fasteners must penetrate through the foam plastic into wood or steel framing and the system must be designed to handle cladding load and wind load, per applicable code. 2Fasteners used for securing the terracotta cladding must penetrate through the foam plastic into wood or steel framing and the system must be designed to handle cladding load and wind load, per applicable code. ESR-1659 | Most Widely Accepted and Trusted Page 5 of 7 TABLE 3—NFPA 285 COMPLYING WALL ASSEMBLIES FOR MAXIMUM 3-INCH-THICK THERMAX™ INSULATION BOARD Base Wall System – Use either 1, 2, 3 or 4 1 – Concrete Wall 2 – Concrete Masonry Wall 3 – Standard Clay Brick Wall 4 – Steel Studs (minimum 3 5/8” deep, minimum 20-gage, Maximum 24-inch o.c., lateral bracing every 4 ft. vertically) with one of the following installed on the interior face side of the stud wall: a. 1 layer or 1/2” or 5/8” Type X gypsum wallboard (interior face) b. W.R Grace’s Monokote Z-3306, 3/8”-thick minimum, Installed Over: i. Cavity Insulation Item 2 or ii. THERMAX™, any thickness c. Intrenational Cellulose Corporation’s Ure-K thermal barrier system (ESR-2110) – 1.25 inches minimum installed over: i. Cavity Insulation Item 2 or ; ii. Dow THERMAX™, any thickness d. Specialty Products, Inc. Flame Seal-TB™ coating applied at 25 mils wet thickness (18 mils dry, 65 ft2/gal) over Cavity Insulation Item 2 e. International Fireproof Technology, Inc. DC 315 applied at 18 wet mils thickness over 4 dry mils of primer over Cavity Insulation Item 2 Floorline Firestopping 4 lb/ft3 Mineral Wool in each stud cavity and at each floorline. Mineral wool to be attached with Z-clips or equivalent (see Figure 4) Cavity Insulation – Use either 1, 2, 3 or a combination of 2 and 3 1 – None 2 – Full stud depth or less thickness of Dow STYROFOAM™ Spray Polyurethane Foam CM2030, CM2045 or CM2060 (ESR-2670). Use exterior sheathing as substrate to apply onto and cover the width of the cavity including inside the stud flange 3 – Fiberglass batt insulation (faced or unfaced) complying with the applicable code Exterior Sheathing – Use either 1, 2 or 3 1 – None 2 – 1/2-inch thick, exterior type gypsum sheathing complying with the applicable code 3 – 5/8-inch thick, exterior type gypsum sheathing complying with the applicable code Water-Resistive Barrier Applied to Exterior Sheathing – Use 1 or 2 1 – None 2 – Any of the following: a. WEATHERMATE™ - Dow Chemical (ESR-2862) b. WEATHERMATE™ Plus – Dow Chemical (NER-640) c. Tyvek® CommercialWrap® - DuPont (ESR-2375) d. Backstop® NT – Dryvit e. Barritech™ VP – Carlisle f. AIR-SHIELD™ LMP (black only) – W.R. Meadows g. Green Guard® Max Building Wrap – Pactiv (ESR-2906) h. Perm-A-Barrier® VPS – W.R. Grace *Note: All barriers to be installed at recommended application rates per manufacturer’s installation instructions Exterior Insulation – Use 1 or 2 1 – None. Exterior Sheathing must be Item 2 or 3 as specified under exterior sheathings above 2 – Dow THERMAX™ Insulation Board (Thickness: 5/8-inch Minimum, 3-inch Maximum) Flashing Flash all exterior insulation joints and veneer tie penetrations with one of the following: 1 – Dow WEATHERMATE™ Flashing – Maximum 4-inch wide 2 – Asphalt or Butyl-based flashing tape – Maximum 4-inch wide Optional: Spray primer to aid in adhesion of either 1 or 2 applied at a maximum of 5-inches wide Exterior Veneer – Use 1, 2, 3 or 4 1 – Metal Composite Material System. Use any Metal Composite Material system that has been successfully tested by the panel manufacturer via NFPA 285 test method. Installed using standard installation techniques. Evidence of testing in accordance with NFPA 285 and/or an ICC-ES report must be submitted to the code official 2 –Terracotta Cladding – Minimum 1 1/4-inch thick installed using standard installation techniques 3 – Metal Exterior Wall Coverings – Including but not limited to steel, aluminum and copper installed using standard installation techniques 4 – Cement Board Siding – Installation in accordance with siding manufacturer installation instructions or an ICC-ES evaluation report for the siding product 5 – StoneLite® wall panels by Stone Panels (ESR-1500) For SI: 1 inch = 25.4 mm. 1Fasteners used for securing the terracotta cladding must penetrate through the foam plastic into wood or steel framing and the system must be designed to handle cladding load and wind load, per applicable code. ESR-1659 | Most Widely Accepted and Trusted Page 6 of 7 Step 1 Step 2 FIGURE 1—TYPICAL WINDOW FLASHING DETAIL Step 1 Step 2 Step 3 FIGURE 2—TYPICAL PENETRATION FLASHING DETAIL—FLANGED FIGURE 3—TYPICAL FLASHING DETAIL—UNFLANGED ESR-1659 | Most Widely Accepted and Trusted Page 7 of 7 FIGURE 4—FIRESTOPPING DETAIL AT FLOOR LINES FOR TYPES I–IV CONSTRUCTION